CN116423929A - 一种单向导湿容尘型过滤材料及口罩 - Google Patents

一种单向导湿容尘型过滤材料及口罩 Download PDF

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CN116423929A
CN116423929A CN202310226238.5A CN202310226238A CN116423929A CN 116423929 A CN116423929 A CN 116423929A CN 202310226238 A CN202310226238 A CN 202310226238A CN 116423929 A CN116423929 A CN 116423929A
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outer layer
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林芳兵
张萌
张靖
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Andanda Industrial Technology Shanghai Co ltd
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Abstract

本发明公开一种单向导湿容尘型过滤材料及口罩，包括由内至外依次固接的内层、中间层和外层；中间层采用纳米纤维膜，中间层的纤维直径小于内层的纤维直径，中间层的平均孔径小于内层的平均孔径；外层采用亲水性纤维制成的起绒针刺布，外层远离中间层的一侧面为起绒结构，外层的亲水性能大于中间层的亲水性能。本申请的过滤材料在内层和中间层之间利用平均孔径的不同构成单向导湿结构，在中间层和外层之间利用亲水性能的不同构成单向导湿结构，使内层面接触到的水单向导至外层，再利用外层起绒结构的蒸腾作用将水快速蒸发和容尘，具有单向导湿能力强、容尘性能高、防护效果好和透气性强的特点，从根本上解决了口罩容易变湿的问题。

Description

一种单向导湿容尘型过滤材料及口罩
技术领域
本申请涉及口罩的技术领域，具体地，涉及一种单向导湿容尘型过滤材料及口罩。
背景技术
在呼吸道传染病流行时，或在粉尘等污染的环境中作业时，佩戴口罩成为人们必备的防护用品。人们呼吸过程中脸部会排汗、口腔会呼气，导致口罩内部短时间内极易变湿，变湿之后的口罩佩戴不舒适且会对防护效果有影响，主要是因为口罩的核心材料是熔喷布，其工作原理是依靠静电层来阻隔和吸附颗粒物，口罩变湿会使熔喷布静电发生衰减，导致口罩防护效果下降。目前的解决方案是提高口罩的更换频率或在口罩内部垫一张纸，提高口罩的更换频次会造成资源浪费和污染环境；在口罩内部垫一张纸会严重影响口罩与佩戴者面部密合性，影响口罩的防护效果以及佩戴的舒适性，因此以上两种方案都没有从根本上解决口罩容易变湿的问题。
发明内容
为解决上述问题的至少一个方面，本发明提供了一种单向导湿容尘型过滤材料，包括由内至外依次固接的内层、中间层和外层；中间层采用纳米纤维膜，中间层的纤维直径小于内层的纤维直径，中间层的平均孔径小于内层的平均孔径；外层采用亲水性纤维制成的起绒针刺布，外层远离中间层的一侧面为起绒结构，外层的亲水性能大于中间层的亲水性能。
通过上述技术方案，将中间层的平均孔径设计为比内层的平均孔径小，由于毛细管效应，产生从内层至中间层的附加压力差，使得水在附加压力差作用下自动从内层流向中间层；将外层的亲水性能设计得大于中间层的亲水性能，使得在中间层和外层之间形成湿润性梯度，产生中间层至外层的附加压力差，在附加压力差的作用下，水从中间层自动流向外层；将外层远离中间层的侧面设计为起绒结构，利用从外层的芯部直接伸展出的毛羽增强外层的毛细效应，使外层中的水快速向外界蒸发，从而保持过滤材料的干燥，另一方面可以将大颗粒物容纳在毛羽结构中，提高本申请过滤材料的容尘性能；采用纳米纤维膜作为中间层起过滤作用，由于纳米纤维膜的纤维直径小，采用机械过滤机制进行过滤，使得过滤材料的阻隔效率高、使用寿命长、透气性好。因此，本申请的过滤材料具有单向导湿能力强、容尘性能高、防护效果好和舒适性好的特点。
优选地，所述内层采用起绒针刺布，内层靠近中间层的一侧面为起绒结构。通过上述技术方案，将内层靠近中间层的一侧面设计的起绒结构起到导湿的作用，将内层的水快速传递到中间层，进一步提高了将水从内层单向导入中间层的能力。
优选地，所述内层采用单面起绒烫光针刺布，内层远离中间层的一侧面采用烫光工艺制成。通过上述技术方案，将内层远离中间层的一侧面，即贴近皮肤的一侧面采用烫光工艺制成，使得该侧面硬挺、光滑和平整，有助于进一步提高接触的舒适性，防止发生本申请的过滤材料接触皮肤时产生刺痛感的情况。
优选地，所述外层采用双面起绒针刺布，外层靠近中间层的一侧面为起绒结构。通过上述技术方案，将外层靠近中间层的一侧面也设计为起绒结构，起到将更多大颗粒物容纳在该起绒结构中的蓬松毛羽结构中，从而进一步提高本申请过滤材料的容尘性能和导湿性能。
优选地，所述中间层包括复合而成的疏水性纳米纤维膜层和亲水性纳米纤维膜层，疏水性纳米纤维膜层与内层固接，亲水性纳米纤维膜层与外层固接。通过上述技术方案，将中间层的纳米纤维膜设计为疏水性纳米纤维膜层和亲水性纳米纤维膜层复合而成，使得在纳米纤维膜中形成湿润性梯度，使得中间层靠近内层一侧的水快速单向导至中间层靠近外层的一侧，从而进一步提高本申请过滤材料的单向导湿能力。
优选地，所述亲水性纳米纤维膜层采用生物可降解共聚物材料制成。通过上述技术方案，将采用生物可降解共聚物材料制成的纳米纤维膜，实现本申请过滤材料的可降解，有助于环保。
优选地，所述疏水性纳米纤维膜层的纤维直径为500～2000nm，亲水性纳米纤维膜层的纤维直径为500～1000nm。通过上述技术方案，保证了纳米纤维膜中的平均孔径较小，从而提高本申请过滤材料的过滤能力和过滤效率。
优选地，所述内层采用疏水性纤维制成，内层的疏水性能大于中间层的疏水性能。通过上述技术方案，采用疏水性纤维制成内层，一方面减少水分进入内层，从而减少本申请过滤材料的变湿情况，另一方面在内层和中间层也形成润湿性梯度，进一步提高水分从内层导向中间层的导湿能力。
优选地，所述内层的纤维直径为10～15μm，外层的纤维直径为15～20μm，外层的平均孔径小于内层的平均孔径。通过上述技术方案，本申请过滤材料在整体上形成直径梯度和差动效应，进一步提高单向导湿能力。
本申请还提供了一种口罩，包括口罩本体，口罩本体采用上述任一所述的一种单向导湿容尘型过滤材料制成。通过上述技术方案，采用上述本申请的过滤材料制成口罩本体，使得口罩具有单向导湿能力强、透气性好、防护效果好和佩戴舒适的特点，从根本上解决了口罩容易变湿的问题。
本发明的一种单向导湿容尘型过滤材料及口罩，具有以下有益效果：
本申请的过滤材料通过在内层和中间层之间利用平均孔径的不同构成单向导湿结构，在中间层和外层之间利用亲水性能的不同构成单向导湿结构，使内层面接触到的水单向导至外层；首次将起绒针刺布用作过滤材料的外层，利用起绒针刺布外层起绒结构的蒸腾作用将外层中的水快速蒸发，从而保持过滤材料的干燥，以及将大颗粒物容纳在毛羽结构中，提高本申请过滤材料的容尘性能；通过将内层采用疏水性纤维，并在其靠近中间层的一侧面设计为起绒结构，以及将中间层设计为由内至外分布的疏水性纳米纤维膜层和亲水性纳米纤维膜层复合而成，使得内层面接触到的水快速单向导至外层，进一步提高本申请过滤材料的单向导湿能力；通过将外层设计为双面起绒结构，一方面有助于提高外层水分的蒸发效率，另一方面起到将更多大颗粒物容纳在起绒结构中的蓬松毛羽结构中，从而进一步提高本申请过滤材料的容尘性能、导湿性能和过滤性能。因此，本申请的过滤材料及口罩具有单向导湿能力强、容尘性能高、防护效果好和舒适性好的特点。
附图说明
为了更好地理解本发明的上述及其他目的、特征、优点和功能，可以参考附图中所示的实施方式。附图中相同的附图标记指代相同的部件。本领域技术人员应该理解，附图旨在示意性地阐明本发明的优选实施方式，对本发明的范围没有任何限制作用，图中各个部件并非按比例绘制。
图1示出了根据本发明实施例的一种单向导湿容尘型过滤材料及口罩的结构示意图。
附图标记说明：
1、内层；2、中间层；21、疏水性纳米纤维膜层；22、亲水性纳米纤维膜层；3、外层。
具体实施方式
以下结合附图对本公开的示范性实施例做出说明，其中包括本公开实施例的各种细节以助于理解，应当将它们认为仅仅是示范性的。因此，本领域普通技术人员应当认识到，可以对这里描述的实施例做出各种改变和修改，而不会背离本公开的范围和精神。同样，为了清楚和简明，以下的描述中省略了对公知功能和结构的描述。
在本文中使用的术语“包括”及其变形表示开放性包括，即“包括但不限于”。除非特别申明，术语“或”表示“和/或”。术语“基于”表示“至少部分地基于”。术语“一个示例实施例”和“一个实施例”表示“至少一个示例实施例”。术语“另一实施例”表示“至少一个另外的实施例”。术语“第一”、“第二”等等可以指代不同的或相同的对象。下文还可能包括其他明确的和隐含的定义。
为了至少部分地解决上述问题以及其他潜在问题中的一个或者多个，本公开的一个实施例提出了一种单向导湿容尘型过滤材料，包括由内至外依次固接的内层1、中间层2和外层3；中间层2采用纳米纤维膜，中间层2的纤维直径小于内层1的纤维直径，中间层2的平均孔径小于内层1的平均孔径；外层3采用亲水性纤维制成的起绒针刺布，外层3远离中间层2的一侧面为起绒结构，外层3的亲水性能大于中间层2的亲水性能。
具体地，如图1所示，内层1优选采用疏水性纤维制成的起绒针刺布，内层1的纤维直径优选为10～15μm，疏水性纤维为聚乙烯、涤纶树脂、聚丙烯中的一种或几种，内层1靠近中间层2的一侧面为起绒结构，起绒结构的长度为0.1～1mm，采用针刺布生产工艺制备时刺针的植针密度为4000～6000针/m；在一些实施例中，内层1采用单面起绒烫光针刺布，内层1远离中间层2的一侧面采用烫光工艺制成。
中间层2采用纳米纤维膜，中间层2的纤维直径小于内层1的纤维直径，中间层2的平均孔径小于内层1的平均孔径，优选地，中间层2的疏水性能小于内层1的疏水性能；在一些实施例中，中间层2包括复合而成的疏水性纳米纤维膜层21和亲水性纳米纤维膜层22，疏水性纳米纤维膜层21采用聚偏氟乙烯、聚丙烯腈、聚砜、聚苯乙烯、聚乳酸中的一种或几种制成，疏水性纳米纤维膜层21的纤维直径为500～2000nm，优选地，疏水性纳米纤维膜层21的纤维直径为500～1000nm，孔隙率为80～85％，厚度为180～200um，疏水性纳米纤维膜层21的疏水性能小于内层1的疏水性能，疏水性纳米纤维膜层21与内层1固接；亲水性纳米纤维膜层22优选采用生物可降解共聚物材料制成，亲水性纳米纤维膜层22采用聚乳酸纳米纤维膜、聚己内酯电纺纤维膜、聚乳酸-羟基乙酸共聚物电纺纤维膜、聚乙烯醇纤维膜、聚苯乙烯纤维膜、聚砜纤维膜、聚丙烯腈纳米纤维膜中的一种或几种制成，亲水性纳米纤维膜层22的纤维直径为500～1000nm，孔隙率为85～90％，厚度为180～200um，亲水性纳米纤维膜层22与外层3固接。
外层3采用亲水性纤维制成的起绒针刺布，亲水性纤维为黏胶纤维或棉纤维，外层3的纤维直径为15～20μm，外层3的平均孔径小于内层1的平均孔径，外层3远离中间层2的一侧面为起绒结构，起绒结构的长度为0.1～1mm，采用针刺布生产工艺制备时刺针的植针密度为4000～6000针/m，外层3的亲水性能大于中间层2的亲水性能，优选地，外层3的亲水性能大于亲水性纳米纤维膜层22的亲水性能。在一些实施例中，外层3采用双面起绒针刺布，外层3靠近中间层2的一侧面也为起绒结构。
本申请还提供了一种口罩，包括口罩本体，口罩本体采用上述任一所述的一种单向导湿容尘型过滤材料制成。
本申请的一种单向导湿容尘型过滤材料的生产方法如下：
步骤1：采用纤维直径为10～15μm的疏水性纤维聚乙烯或涤纶树脂或聚丙烯材料，利用针刺布生产工艺以植针密度为4000～6000针/m，制备单面起绒针刺布；
步骤2：利用烫光工艺对步骤1中得到的单面起绒针刺布的非起绒面进行烫光工序，形成单面起绒烫光针刺布；
步骤3：利用静电纺丝工艺，在步骤2中得到的单面起绒烫光针刺布的起绒面上，接纳采用纤维直径为500～2000nm的聚偏氟乙烯或聚丙烯腈或聚砜或聚苯乙烯或聚乳酸制成的孔隙率为80～85％，厚度为180～200um的疏水性纳米纤维膜层21；
步骤4：利用静电纺丝工艺，在步骤3中的疏水性纳米纤维膜层21上，接纳采用纤维直径为500～1000nm的聚乳酸或聚己内酯或聚乳酸-羟基乙酸共聚物或聚乙烯醇或聚苯乙烯或聚砜或聚丙烯腈制成的孔隙率为85～90％，厚度为180～200um亲水性纳米纤维膜层22；
步骤5：采用纤维直径为15～20μm的亲水性纤维黏胶纤维或棉纤维材料，利用针刺布生产工艺以植针密度为4000～6000针/m，制备双面起绒针刺布；
步骤6：采用超声波焊接工艺按照本申请过滤材料的结构顺序将步骤2中得到内层1、步骤3和4得到的中间层2和步骤5中得到外层3复合在一起。
以上已经描述了本公开的各实施例，上述说明是示例性的，并非穷尽性的，并且也不限于所披露的各实施例。在不偏离所说明的各实施例的范围和精神的情况下，对于本技术领域的普通技术人员来说许多修改和变更都是显而易见的。本文中所用术语的选择，旨在最好地解释各实施例的原理、实际应用或对市场中的技术改进，或者使本技术领域的其它普通技术人员能理解本文。

Claims (10)

1.一种单向导湿容尘型过滤材料，其特征在于：包括由内至外依次固接的内层(1)、中间层(2)和外层(3)；中间层(2)采用纳米纤维膜，中间层(2)的纤维直径小于内层(1)的纤维直径，中间层(2)的平均孔径小于内层(1)的平均孔径；外层(3)采用亲水性纤维制成的起绒针刺布，外层(3)远离中间层(2)的一侧面为起绒结构，外层(3)的亲水性能大于中间层(2)的亲水性能。
2.根据权利要求1所述的一种单向导湿容尘型过滤材料，其特征在于：所述内层(1)采用起绒针刺布，内层(1)靠近中间层(2)的一侧面为起绒结构。
3.根据权利要求2所述的一种单向导湿容尘型过滤材料，其特征在于：所述内层(1)采用单面起绒烫光针刺布，内层(1)远离中间层(2)的一侧面采用烫光工艺制成。
4.根据权利要求1所述的一种单向导湿容尘型过滤材料，其特征在于：所述外层(3)采用双面起绒针刺布，外层(3)靠近中间层(2)的一侧面为起绒结构。
5.根据权利要求1所述的一种单向导湿容尘型过滤材料，其特征在于：所述中间层(2)包括复合而成的疏水性纳米纤维膜层(21)和亲水性纳米纤维膜层(22)，疏水性纳米纤维膜层(21)与内层(1)固接，亲水性纳米纤维膜层(22)与外层(3)固接。
6.根据权利要求5所述的一种单向导湿容尘型过滤材料，其特征在于：所述亲水性纳米纤维膜层(22)采用生物可降解共聚物材料制成。
7.根据权利要求5所述的一种单向导湿容尘型过滤材料，其特征在于：所述疏水性纳米纤维膜层(21)的纤维直径为500～2000nm，亲水性纳米纤维膜层(22)的纤维直径为500～1000nm。
8.根据权利要求1所述的一种单向导湿容尘型过滤材料，其特征在于：所述内层(1)采用疏水性纤维制成，内层(1)的疏水性能大于中间层(2)的疏水性能。
9.根据权利要求1所述的一种单向导湿容尘型过滤材料，其特征在于：所述内层(1)的纤维直径为10～15μm，外层(3)的纤维直径为15～20μm，外层(3)的平均孔径小于内层(1)的平均孔径。
10.一种口罩，其特征在于：包括口罩本体，口罩本体采用权利要求1至9任一所述的一种单向导湿容尘型过滤材料制成。
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